design exploration and robust design - ansys uk... · robust design • taking the variation of...

© 2011 ANSYS, Inc. November 14, 2011

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Design Exploration and Robust Design

Mark KeatingTechnical Services, ANSYS UK


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Drive WorkbenchWorkbench

Parametric, persistent, and scriptable integration platform

DX

ANSYS Workbench

Solvers

DesignXplorer

Drives Workbench to explore and optimize your design

EKM

Drives Workbench, manages your simulation process and data, unifies your distributed teams, and more


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Agenda

• What is Robust Design?

• At ANSYS

• Workbench Principles

• DesignXplorer

• ANSYS Vision


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What is Robust Design?


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Evolution of Simulation

Single Solve• Solves a single simulation with only

a single physics• Users are interested in solution

robustness, speed, accuracy, ease of use and engineering resultsDoesn’t account for

physics interactions

“Virtual Prototyping” typically requires looking at multiple physics, often within the same solver or by coupling solvers. This single physics approach is often not enough.


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Single Multiphysics Solve• Solves a single simulation involving

multiple physics• Users are still interested in solution

robustness, speed, accuracy, ease of use and engineering results

• And the ease and power of the physics coupling

Doesn’t provide direction for design

improvement

Is this the best design? How can I improve performance? Can I reduce weight or cost? What is limiting performance? Is this a robust design?


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?

??

“What If” Study• User adjusts inputs and investigates

results• Builds on previous expectations,

adds requirement of easy and robust parametric updates and comparative reports

Solutions compared, but design is not well

understood and no optimum is found

Need a more scientific and automated way to decide which points to solve

Need a way to interpolate between these points


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Difficult to optimize a design with many inputs and goals


Design Exploration• Scientific methods to explore the

design space fully• Amplifies the importance of the

previous technology• Adds requirements for: robust efficient

& affordable distributed solve, sensitivity and correlation, DOE and response surface technology, mesh morphing, charting and reporting

Response Surface

Provides design understanding, but optimization is not

automated


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Optimization• Searches the design space for optimal

candidates, given user-defined goals and priorities

• Amplifies the importance of the previous technology

• Adds requirements for: advanced optimization algorithms to efficiently search for candidates, comparative reporting

Real-world inputs typically have some variation and may require a more “robust design” goal

Solutions may be too sensitive to input

variability


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Robust Design• Taking the variation of inputs into account, and

seeking a design with a probabilistic goal

• RDO => Min standard deviation of the results• Six Sigma => Optimal design within a safe domain• There are other Robust Design methods/goals…

• Amplifies the importance of the underlying Workbench and solver technologies

• Adds requirements for: probabilistic parameters, specific probabilistic optimization algorithms


Input distribution

Output distribution


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The Path to Robust Design

Single Physics Solution•Accuracy, robustness, speed…

MultiphysicsSolution•Integration Platform

“What if” Study•Parametric Platform

Design Exploration•DOE, Response Surfaces, Correlation, Sensitivity, etc.

Optimization•Algorithms

Robust Design•Probabilistic Algorithms•Adjoint solver methods


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ANSYS Vision

ANSYS Has a very clear vision for Simulation Driven Product Development!

• Best-in-class solvers combined for multiphysics

• Ease of use, knowledge capture, integration platform…

• Parametric, persistent, automated

• Design exploration & robust design!


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Design Exploration and Robust Design at ANSYS


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Optimization tools at ANSYS

• ANSYS DesignXplorer– Unified Workbench solution

• ANSYS Fluent – Has built-in morphing and

optimization tools– Has an adjoint solver

• ANSOFT Optimetrics• ANSYS MAPDL

– DX VT• And more

Baseline Design

Optimized Design


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ANSYS DesignXplorerIntegral with Workbench

• Parametric multiphysicsmodeling with automated updates

• Bi-directional CAD, RSM, scripting, reporting and more...


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Optimization PartnersANSYS simulation software has been

effectively used to drive innovation in concert with optimization partners

• MATLAB (Mathworks)

• ModeFrontier (Esteco)

• OptiSLang (Dynardo)

• RBF-Morph

• Sculptor (Optimal)

• Sigma Technology (IOSO)

• TOSCA (FE-DESIGN)

• Qfin (Qfinsoft)

• and more…


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Workbench Principles

(It’s built for SDPD)


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ANSYS Workbench Schematic Workflow


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Workbench

Integrates ANSYS tools and solvers

Parametric, persistent and scriptable environment


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DesignXplorer in Workbench(It’s built for SDPD)


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ANSYS DesignXplorer

DesignXplorer is everything under this Parameter bar…

• Low cost & easy to use!

• It drives Workbench

• Improves the ROI!

DX

ANSYS Workbench

Solvers


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ANSYS DesignXplorer Design of Experiments

With little more effort than for a single run, you can use DesignXplorer to

create a DOE and run many variations.


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Correlation Matrix

Understand how your parameters are correlated/influenced by other parameters!


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Sensitivity

Understand which parameters your

design is most sensitive to!


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Response Surface

Understand the sensitivities of the output parameters (results) wrt

the input parameters.3D Response

2D Slices Response


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Goal-Driven Optimization

Use an optimization algorithm or screening to understand

tradeoffs or discover optimal design candidates!


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Robustness Evaluation

Input parameters have variation!

Output parameters vary also!

Understand how your performance will vary

with your design tolerances?

Make sure your design is robust!

Six Sigma, TQM

Predict how many parts will

likely fail?

Understand which inputs require the greatest control?


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ANSYS DesignXplorerInitial vs. Optimized Design

Output Initial Design Optimized

Tt Ratio 1.116 1.126

pt Ratio 1.674 1.709

η [%] 71.65 76.25

Power [MW] 1.208 1.268

Engineers can easily appreciate the value of

understanding.


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DesignXplorer Vision

(It’s built for SDPD)


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Engineers face numerous obstacles that prevent them from using optimization fully

Our plans are largely based on removing those obstacles so our customers can get more out of simulation

Remove the Road Blocks

Do you use optimization software?

Matlab16%

18.6%41.9%

21.8%


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Many ways to reduce the time requirements

• Speedup of individual components– Geometry import, meshing, solve, etc.

• Speedup between design points– “DOE Sorting” at 14.0 – Mesh morphing

• Reduce the number of design points required– Improved Sparse Grid DOE at 14.0– New Auto-Kriging at 14.0– New KMOGA adaptive optimization coming at 14.5– Researching ways to use Adjoint information or ROM

to dramatically reduce the number of solves required

• HPC to distribute the solve– New distributed design point solve with RSM at 14.0

Running all those design points takes too long!

Dynamic convergence

feedback

Resolution w/ fewer

points

R14


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Removing RoadblocksEasier to build a parametric model

– “Pervasive Parameters” across WB• Manufacturable values, R14• Extend discrete parameters, R15

– Material selection, Booleans, string parameters, etc.

• System Level Modeling, ROM, RS Systems, etc.

Easier to connect various tools together– Workbench + External Connection + SDK– ANSYS ICEM CFD Meshing at R14.5– Extend the External Connection

Easier access to resources– Hardware

• Cloud computing– Software Licensing

• Simultaneous Design Point (SDP) packs, R14.5

R14


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~1/3rd of Engineers would prefer to use their own algorithms for Optimization

Algorithms R15

• Opening up our Optimization Platform (R15)– Matlab optimization toolbox– API for customized optimization algorithms– Flexible process with custom cost functions and convergence

criteria• This flexibility will be in addition to our “out of the box”

functionality designed to please the other 2/3rds.


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• New Charts– Added 2D slices, local

sensitivity curves and convergence plots; R14

– Significant enhancements planned

Charting & Reporting

R14

R14

• Unified Reporting– Auto-generate project level reports, R14– Strategic theme for R15


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Strategic Theme• Already available

– Six Sigma analysis– Sensitivity / Determination

• Development – Adjoint methods

Robust Design

R12

High sensitivity – changes to shape have a big effect on drag

Low sensitivity

High sensitivity – Shape on Downforce

R14


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The Path to Robust Design

Single Physics

Multiphysics

“What if” Study

Design Exploration

Optimization

Robust Design

• Build on the solid foundation of Workbench as a platform for parametric simulation

• Develop DX as an optimization platform• Build up to probabilistic optimization


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Thank You!

[email protected]

We have also created a DesignXplorer user group on Linked-In

Search Groups for “DesignXplorer” to join.

design exploration and robust design - ansys uk... · robust design • taking the variation of...

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